BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a liquid injection apparatus for atomizing liquid
and injecting the atomized liquid into a liquid injection space.
2. Description of the Related Arts
[0002] As such liquid injection apparatuses, a fuel injection apparatus for an internal-combustion
engine is known. The fuel injection apparatus for the internal-combustion engine is
a so-called electrically controlled fuel injection apparatus comprising a pressurizing
pump for pressurizing liquid and an injection valve, and has been widely and practically
in use. However, as the electrically controlled fuel injection apparatus is configured
in such a manner that the fuel pressurized by the pressurizing pump is injected from
the injection port of the electromagnetic injection valve, the droplet size of the
injected fuel is relatively large, about 100 µm at minimum, and further the sizes
are not uniform. Such large droplet sizes or uneven droplet sizes of the fuel increase
incomplete combustion of fuel when the fuel is burned, thereby causing the increase
in toxic emission.
[0003] On the other hand, as Japanese Patent Application Laid-open (
kokai) No. 54-90416 discloses, a droplet eject apparatus is proposed, wherein the liquid
in a liquid supply passage is pressurized by operation of a piezoelectric element
to produce ultra-fine droplets of liquid and these droplets of liquid are ejected
from an eject port. Apparatuses of the type described use the principle of the ink
jet eject apparatus disclosed, for example, in Japanese Patent Application Laid-open
(
kokai) No. Hei6-40030, or others. In the apparatus, the size of the ejected droplet (the
droplet of injected fuel) can be reduced and can be uniform, when compared to the
above-mentioned electrically controlled fuel injection apparatus. Therefore, this
apparatus can be said to be an excellent apparatus in atomizing fuel.
[0004] When the ink jet eject apparatus is used under a relatively steady-state environment
with less change in the temperature or pressure (for example, in an office room, or
school), it can give its intended performance to inject liquid in the form of droplets
of liquid. However, if it is used under such an environment that fluctuates heavily
caused by fluctuation of operating conditions, like an internal-combustion engine,
it is generally difficult for the apparatus to fully give its intended performance
to atomize the fuel. Therefore, no liquid (fuel) injecting apparatus has so far been
provided which fully succeeds in atomizing liquid and injecting the liquid in the
form of droplets of liquid, by means of using the principle of the ink jet eject apparatus,
for a mechanical apparatus with heavily fluctuating environment like an internal-combustion
engine.
[0005] When such a liquid injection apparatus is applied to mechanical apparatuses like
an internal-combustion engine, the liquid injection apparatus is required to securely
and stably supply the amount of injection of the liquid required by the mechanical
apparatus, and at the same time, to inject the liquid at the injection timing required
by the mechanical apparatus without delay. However, since such liquids injecting apparatuses
carry out injecting by means of increasing or reducing the pressure of liquid, air
bubbles are easily formed in the liquid, and if such air babbles are not removed before
they become large, the pressure of the liquid cannot be increased as expected. Therefore,
the apparatus cannot satisfy the requirements as to the amount of injection and the
injection timing.
SUMMARY OF THE INVENTION
[0006] It is therefore the object of the present invention to provide a liquid injection
apparatus capable of stably accomplishing atomization of liquid and injecting the
liquid in the form of uniform minute droplets of liquid. Another object of the present
invention is to provide a liquid injection apparatus, which is configured to have
the capability of stably injecting liquids even under conditions that the use environment
for the liquid injection apparatus such as liquid injection space heavily and suddenly
fluctuates. A further object of the present invention is to provide a liquid injection
apparatus, which can inject the intended amount of injection of liquid at the intended
injection timing, by means of preventing air babbles from being formed in the liquid
within the liquid injection apparatus.
[0007] In order to achieve the above objects, according to a first aspect of the present
invention, there is provided a liquid injection apparatus comprising an injection
device including a liquid ejection nozzle having one end exposed to a liquid injection
space, a piezoelectric/electrostrictive element, a chamber connected to the other
end of the liquid ejection nozzle, the chamber having a volume changed by the operation
of the piezoelectric/electrostrictive element, a liquid supply passage connected to
the chamber, and a hollow cylindrical liquid filling port allowing the liquid supply
passage to communicate with the exterior; pressurizing means for pressurizing liquid;
an electro-magnetic ejection valve to which liquid pressurized by the pressurizing
means is supplied, the electro-magnetic ejection valve including a solenoid valve
and an ejection hole which is opened or closed by the solenoid valve, the electro-magnetic
ejection valve ejecting the pressurized liquid through the ejection hole when the
solenoid valve is opened; and a hermetically sealed space forming member for forming
a hollow cylindrical hermetically sealed space between the ejection hole of the electro-magnetic
ejection valve and the liquid filling port of the injection device, the hermetically
sealed space having substantially the same diameter as the diameter of the liquid
filling port; liquid ejected from the electro-magnetic ejection valve being atomized
by change of volume of the chamber and injected in the form of droplets from the liquid
ejection nozzle into the liquid injection space, wherein the electro-magnetic ejection
valve is configured to eject liquid ejected from the ejection hole in a direction
having a predetermined angle relative to a center axis of the hollow cylindrical hermetically
sealed space, such that the distance of the liquid from the center axis increases
accordingly as the distance from the ejection hole toward the liquid filling port
increases.
[0008] By virtue of such a configuration, the liquid pressurized by the pressurizing means
is ejected from the electro-magnetic ejection valve into the injection device, and
then the liquid is injected from the liquid ejection nozzle with being atomized by
means of volume change of the chamber in the injection device.
[0009] In this case, the size of the atomized droplet varies depending on physical properties,
such as a pressure to be applied to the liquid, an amplitude and/or a frequency of
the vibration caused by the piezoelectric/electrostrictive element, the shape and/or
dimension of a flow path, and the viscosity/surface tension of the liquid. However,
if the period of vibration applied to the liquid is smaller than the time required
for the liquid , in the vicinity of the end portion of the liquid ejection nozzle
(the opening exposed to the liquid injection space), to travel by the length equivalent
to the diameter of the end portion of the liquid ejection nozzle, the size of the
droplet to be ejected is almost less than the diameter of the end portion of the liquid
ejection nozzle. Therefore, for example, if the diameter of the end portion (opening)
of the liquid ejection nozzle exposed to the liquid injection space is designed to
be less than tens of µm's, the liquid injection apparatus will be able to inject droplets
of liquid which are atomized (formed) into extremely uniform small pieces, and, for
example, if the apparatus is used as a fuel injection apparatus for an internal-combustion
engine, the fuel consumption of the internal-combustion engine can be improved and
toxic emission can be reduced, as the apparatus can atomize (form) the injecting fuel
into droplets of liquid having an appropriate diameter.
[0010] Moreover, according to the above-mentioned configuration, since the pressure required
for injecting liquid is generated by pressurizing means, the apparatus can stably
inject and supply the liquid in the intended form of very small particles, even if
the environment for the liquid injection space (for example, the pressure and temperature)
is abruptly changed due to changes in operating conditions for the machine to which
the apparatus is applied.
[0011] Furthermore, in the conventional carburetor, the flow rate of the fuel (liquid) is
determined corresponding to the flow rate of the air in the space within the intake
pipe, that is the liquid droplet ejecting space, and the degree of atomization varies
depending on the flow rate of the air, however, the liquid injection apparatus according
to the present invention can eject only the required amount of the fuel (liquid) which
keeps satisfactory atomized state, regardless of the flow rate of the air. In addition,
the liquid injection apparatus according to the present invention does not require
a compressor for supplying assist air, unlike the conventional apparatuses which promote
the atomization of the fuel by means of supplying assist air to the nozzle of the
fuel injector. This is one of the reasons for the possibility of embodying the apparatus
at low cost according to the apparatus of this invention.
[0012] Also, in the above-mentioned configuration, between the ejection hole in the electro-magnetic
ejection valve and the liquid filling port in the injection device, a hollow-cylindrical
hermetically sealed space is formed, which has substantially the same diameter as
the liquid filling port, and the shape of which is a hollow cylinder, by the hermetically
sealed space forming member, and the liquid from the ejection hole is ejected in the
direction having a predetermined angle to the center axis (of the hollow-cylindrical
hermetically sealed space), so that the distance of the liquid (droplets) from the
center axis of the hollow cylindrical hermetically sealed space increases, as the
distance from the ejection hole to the liquid filling port increases.
[0013] As a result, as the flow of the ejected liquid is generated in a wide area of the
hollow cylindrical hermetically sealed space, air bubbles are particularly hard to
stay in corners in the vicinity of the ejection hole in the electro-magnetic ejection
valve in the hollow cylindrical hermetically sealed space, or air bubbles formed at
the corners are easily and promptly removed, before they become larger. Therefore,
in this liquid injection apparatus, since the pressure rise of the liquid is hardly
hindered by air bubbles, the pressure of the liquid can be increased as expected,
and the apparatus can inject the required amount of droplets of liquid at the required
injection timing according to the requirements of mechanical apparatuses.
[0014] In this case, the preferred angle formed between the flow line of the droplets of
liquid ejected from the eject port and the axis of the hollow cylindrical hermetically
sealed space, i.e., the predetermined angle θ is preferably 5° or more and 30° or
less.
[0015] In other words, if the predetermined angle θ is smaller than 5°, since fluid (including
air) is easily stay at corners in the vicinity of the electro-magnetic ejection valve
in the hollow cylindrical hermetically sealed space, air bubbles are easily formed
at the corners, and on the contrary, if the predetermined angle θ is larger than 30°,
the substantial traveling distance of the liquid ejected from the ejection hole till
it arrives at the liquid supply passage becomes long, thereby retarding the rise of
the liquid pressure in the liquid supply passage, and consequently making it difficult
for the ejection nozzle to inject droplets of liquid at the intended injection timing.
[0016] Preferably, by the time when liquid ejected from the electro-magnetic ejection valve
is injected through the ejection nozzle into the liquid injection space, a flow of
the liquid is bent at substantially right angles at least once.
[0017] Such a configuration can be embodied, for example, by means of arranging a liquid
filling port and a liquid supply passage such that the flowing direction of the liquid
which passes through the liquid filling port intersects the flowing direction of the
liquid which passes through the liquid supply passage at right angles, and also arranging
the liquid supply passage and a chamber such that the liquid which passes through
the liquid supply passage is introduced into the chamber after being bent at generally
right angles, or arranging the chamber and the ejection nozzle such that the liquid
which passes through the chamber is bent at generally right angles and flows into
the ejection nozzle.
[0018] According to configurations of the type described, as the flow of the liquid ejected
from the electro-magnetic ejection valve is bent at generally right angles at least
once, the pulsation of the liquid pressure within the injection device incidental
to the opening operation of the electro-magnetic ejection valve is reduced, and/or
the distribution of liquid pressure in the injection device becomes equalized (the
liquid pressure is distributed equally), the apparatus can stably inject droplets
of liquid. Especially, when the injection device has a plurality of chambers connected
to a common liquid supply passage, if the flow of the liquid ejected from the electro-magnetic
ejection valve is bent at generally right angles by the liquid filling port and the
liquid supply passage, the pressure of the liquid within the liquid supply passage
will be stabilized, and the pressure of the liquids within the individual chambers
will also be stabilized, thus resulting in acquisition of equal sizes of droplets
of liquid ejected from the ejection nozzle connected to the chambers.
[0019] The liquid supply passage preferably includes a plane section which is opposed to
(confronts) a virtual plane defined by a section at which the liquid supply passage
is connected to the liquid filling port, the plane section extending in parallel with
the virtual plane, and the electro-magnetic ejection valve is preferably arranged
such that an ejection flow line of liquid ejected from the ejection hole intersects
the plane section of the liquid supply passage without intersecting a side wall of
the hollow cylindrical hermetically sealed space formed by the hermetically sealed
space forming member, or a side wall which is created by virtually extending the side
wall of the hermetically sealed space down to the plane section of the liquid supply
passage.
[0020] According to this configuration, as the liquid ejected from the electro-magnetic
ejection valve arrives at the plane section of the liquid supply passage with keeping
its kinetic energy (flow velocity) in high state, the liquid is strongly reflected
in the plane section toward the filling port and the vicinity side of the ejection
hole in the hollow cylindrical hermetically sealed space formed by the hermetically
sealed space forming member. As a result, since the flow of the reflected liquid can
remove air bubbles staying at corner sections in the vicinity of the ejection hole
in the hollow cylindrical hermetically sealed space, the amount of air bubbles in
the liquid can be reduced. Accordingly, in the liquid injection apparatus, since it
will be much more difficult for air bubbles to hinder the rise of the liquid pressure,
and the pressure of the liquid can be increased as expected, the liquid injection
apparatus can inject the specified amount of liquid in the form of droplets of liquid
at the specified injection timing, as mechanical apparatuses require.
[0021] Preferably, the ratio (V/Q) is 0.03 or less where V represents a volume (cc) of a
liquid flow passage extending from the electro-magnetic ejection valve (portion of
the ejection hole) up to the leading end of the ejection nozzle of the injection device,
and Q represents the quantity of ejection per unit time (cc/minute) of liquid ejected
from the electro-magnetic ejection valve.
[0022] Here, the fluid volume formed from the electro-magnetic ejection valve to the leading
end of the ejection nozzle of the injection device means the total volume of the hermetically
sealed space for the hermetically sealed space forming member, liquid filling port,
liquid supply passage, chamber and liquid ejection nozzle (in the case where the liquid
supply passage and the chamber are connected with a liquid introduction hole, the
volume of the liquid introduction hole is included in the total volume).
[0023] The reason for setting the size of the ratio (V/Q) as described above, is that if
the ratio (V/Q) is larger than 0.03, the volume V (cc) becomes excessively large to
the flow rate Q (cc/minute), and the time period between the timing when the device
starts ejecting the liquid by the electro-magnetic ejection valve and the timing when
the pressure of the liquid within the ejection nozzle in the injection device starts
rises becomes too long, thereby causing a difficulty in injecting droplets of liquid
at the intended timing.
[0024] In order to attain the above objects, according to a second aspect of the present
invention there is provided a liquid injection apparatus comprising an injection device
including a liquid ejection nozzle having one end exposed to a liquid injection space,
a piezoelectric/electrostrictive element operated by a drive voltage signal, a chamber
connected to the other end of the liquid ejection nozzle, the chamber having a volume
changed by the operation of the piezoelectric/electrostrictive element, a liquid supply
passage connected to the chamber, and a liquid filling port allowing the liquid supply
passage to communicate with the exterior; pressurizing means for pressurizing liquid;
an electro-magnetic ejection valve to which liquid pressurized by the pressurizing
means is supplied, the electro-magnetic ejection valve including a solenoid valve
driven by a valve drive signal and an ejection hole which is opened or closed by the
solenoid valve, the electro-magnetic ejection valve ejecting the pressurized liquid
through the ejection hole into the liquid filling port of the injection device when
the solenoid valve is driven; and an electric control unit including drive voltage
signal generation means for generating the drive voltage signal, and valve drive signal
generation means for generating the valve drive signal; liquid ejected from the electro-magnetic
ejection valve being atomized by change of volume of the chamber and injected in the
form of droplets from the liquid ejection nozzle into the liquid injection space,
wherein the electric control unit is configured to start generating the drive voltage
signal at a point of time prior to the time when the pressure of liquid within the
liquid supply passage starts to rise as a result of generation of the valve drive
signal.
[0025] By virtue of this configuration, at the instant when the pressure of the liquid within
the liquid supply passage starts rising by the generation of the valve drive signal,
i.e., at the instant when the ejection nozzle in the injection device likely starts
injecting droplets of liquid, the piezoelectric/electrostrictive element is already
driven by the drive voltage signal, and oscillation energy (vibration energy) is added
to the liquid, therefore, the device can securely inject atomized droplets of liquid
from the beginning of injecting liquid.
[0026] Similarly, according to a third aspect of the present invention, the electric control
unit is configured to continue generation of (i.e. to generate) the drive voltage
signal till a point of time posterior to the time when the valve drive signal comes
to an end.
[0027] By virtue of this configuration, since the pressure of the liquid within the liquid
supply passage is kept higher than the pressure required for injecting for a while
even after the valve drive signal is ended, at the instant when the ejection nozzle
in the injection device keeps injecting droplets of liquid, the piezoelectric/electrostrictive
element is still driven by the drive voltage signal, and oscillation energy is still
applied to the liquid. Therefore, the device can securely atomize and inject the liquid,
(until the injection actually stops) even after the valve drive signal is ended.
[0028] Preferably, the injection device comprises a plurality of the liquid ejection nozzles
such that the directions of injection of liquid droplets injected from the plurality
of liquid ejection nozzles are parallel to each other.
[0029] According to this, the droplets of liquid ejected from the individual ejection nozzle
to the liquid injection space will not cross each other, so that droplets of liquid
can be prevented from becoming large by colliding with each other, and the satisfactory
atomizing state of injecting droplets of liquid can be maintained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The above and other objects, aspects, features and advantages of the present invention
will become more apparent from the following detailed description when taken in conjunction
with the accompanying drawings, in which:
Fig. 1 is a schematic view of a liquid injection apparatus applied to an internal-combustion
engine with respect to an embodiment of the present invention;
Fig. 2 is a diagram showing an electro-magnetic ejection valve and an injecting unit
shown in Fig. 1;
Fig. 3 is an enlarged cross-sectional view of the electro-magnetic ejection valve
and the injecting unit in the vicinity of the leading end portion of the electro-magnetic
ejection valve shown in Fig. 2;
Fig. 4 is a plan view of the injection device shown in Fig. 2;
Fig. 5 is a cross-sectional view when the plane along the line 1-1 shown in Fig. 4
cuts through the injection device;
Fig. 6 is a timing chart in which (A), (B), (C) and (D) show an valve drive signal
to be added to the electro-magnetic ejection valve, the liquid pressure within a liquid
supply passage, a drive voltage signal to be added to a piezoelectric/electrostrictive
element, and an valve opening timing for an intake valve, respectively;
Fig. 7 shows the state of the liquid to be injected from the liquid injection apparatus
according to the present invention as shown in Fig. 1;
Fig. 8 is a graph showing the change in the amount of displacement of the piezoelectric/electrostrictive
element when the frequency of the drive voltage signal to be added to the piezoelectric/electrostrictive
element is changed;
Fig. 9 is a conceptual diagram showing the flow of the liquid in a modified embodiment
of the liquid injection apparatus shown in Fig. 1; and
Fig. 10 is a conceptual diagram showing the flow of the liquid in another modified
embodiment of the liquid injection apparatus shown in Fig. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] With reference to the drawings, description will now be made of embodiments of a
liquid injection apparatus (liquid spraying apparatus, liquid supplying apparatus,
liquid droplet ejecting apparatus) in accordance with the present invention. Fig.
1 shows a schematic configuration for the liquid injection apparatus applied to an
internal-combustion engine as a mechanical apparatus, which requires atomized liquid.
[0032] This liquid injection apparatus 10 is an apparatus for injecting atomized liquid
(liquid-fuel, for example, gasoline, hereinafter it may be simply referred to as "fuel")
into a fuel injecting space 21 formed by an intake pipe (or a suction port) 20 in
an internal-combustion engine, toward the back face of an intake valve 22 for the
internal-combustion engine, and comprises a pressurizing pump (fuel pump) 11 as pressurizing
means, a liquid supply pipe (fuel piping) 12 provided with (or pipe 12 having therein)
the pressurizing pump, a pressure regulator 13 provided on the eject side of the pressurizing
pump of the liquid supply pipe 12, an electro-magnetic ejection valve 14, an injecting
unit (spraying unit) 15 having a chamber, at least a piezoelectric/electrostrictive
element being formed on its wall face, for atomizing the liquid to be injected into
the fuel injecting space 21 and an ejection nozzle, and an electric control unit 30
which supplies an valve drive signal and a drive voltage signal for changing the volume
of the chamber (for operating the piezoelectric/electrostrictive element), to the
electro-magnetic ejection valve 14 and the injecting unit 15, respectively, as drive
signals.
[0033] The pressurizing pump 11 is connected to the bottom section of a liquid storage tank
(fuel tank) 23, and comprises a lead-in section 11a, to which the fuel is supplied
from the liquid storage tank 23, and an eject section 11b, which is connected to the
liquid supply pipe 12. This pressurizing pump 11 introduces the fuel in the liquid
storage tank 23 through the lead-in section 11a, and pressurizes the fuel so that
the pressure of the fuel can become larger (to obtain a pressure larger) than the
pressure required for injecting droplets of liquid into the liquid injection space
21 (this pressure is called "eject pressure of pressurizing pump) through the pressure
regulator 13, electro-magnetic ejection valve 14 and injecting unit 15 (even if the
piezoelectric/electrostrictive element of the injecting unit 15 is not operated),
and then ejects the pressurized fuel from the eject section 11b into the liquid supply
pipe 12.
[0034] The pressure within the intake pipe 21 is given to the pressure regulator 13 by piping
which is not shown in the drawing, and based on this given pressure, the pressure
regulator 13 is configured so as to reduce (or regulate) the pressure of the fuel
pressurized by the pressurizing pump 11 to adjust the pressure of the fuel within
the liquid supply pipe 12 at the position between the pressure regulator 13 and the
electro-magnetic ejection valve 14 in order to make the pressure higher than the pressure
within the intake pipe 21 by the specified (constant) pressure ( This adjusted pressure
is called "regulated pressure".). As the result of this configuration, when the electro-magnetic
ejection valve 14 is opened for the specified time, the fuel is injected into the
intake pipe 21 regardless the pressure within the intake pipe 21, by the fuel amount
which is generally in proportion to the specified time.
[0035] The electro-magnetic ejection valve 14 is a conventionally well-known fuel injector
(electro-magnetic injection valve), which has been widely adopted in an electrically
controlled fuel injection apparatus for an internal-combustion engine. Fig. 2 is a
front view of the electro-magnetic ejection valve 14, showing a cross-section formed
by cutting through the leading end of the ejection valve by a plane including the
center line of the electro-magnetic ejection valve 14, and also showing a cross-section
formed by cutting through by the same plane as the above the injecting unit 15 secured
to the electro-magnetic ejection valve 14. Also, Fig. 3 is an enlarged cross-sectional
view of the electro-magnetic ejection valve 14 and the injecting unit 15 in the vicinity
of the leading end of the electro-magnetic ejection valve 14 shown in Fig. 2.
[0036] As shown in Fig. 2, this electro-magnetic ejection valve 14 comprises a liquid lead-in
port 14a connected to the liquid supply pipe 12, an external barrel 14c forming a
fuel passage 14b linking to (communicating with) the liquid lead-in port 14a, a needle
valve 14d which functions as a solenoid valve, and an electromagnetic mechanism for
driving the needle valve 14d, which is not shown in the drawing. As shown in Fig.
3, a conical-shape valve seat 14c-1, the shape of which is generally the same as the
leading end of the needle valve 14d, is provided on the center of the leading end
of the external barrel 14c, and also, a plurality of ejection holes 14c-2 (through
holes), which make the inside of the external barrel 14c (i.e. the fuel passage 14b)
communicate with the outside of the external barrel 14c, are provided in the vicinity
of the top (leading end) of the valve seat 14c-1. These ejection holes 14c-2 are tilted
by the angles θ to the axis CL of the needle valve 14d (i.e. to the axis CL of the
electro-magnetic ejection valve 14). Although not shown in the drawing, when the external
barrel 14c is viewed from the direction along the axis CL, the plurality of ejection
holes 14c-2 are arranged on the circumference of the same circle at (with) a constant
interval.
[0037] According to the above-mentioned configuration, in the electro-magnetic ejection
valve 14, the needle valve 14d is driven by the electromagnetic mechanism and opens
or closes the ejection hole 14c-2, and when the ejection hole 14c-2 is opened, the
fuel in the fuel passage 14b is ejected (injected) through the ejection hole 14c-2.
The fuel to be ejected as described above is injected as if spreading along the side
face of a cone with the axis CL as its center (i.e. outer side face of the shape formed
by the ejected liquid becomes substantially a cone), because the ejection hole 14-2c
is tilted to the axis CL of the needle valve 14d.
[0038] As shown in Fig. 2, the injecting unit 15 includes an injection device 15A, an injection
device stationary plate 15B, a retainer unit 15C for retaining the injection device
stationary plate 15B, and a sleeve 15D for securing the leading end of the electro-magnetic
ejection valve 14.
[0039] As shown in Fig. 4 which is a plan view of the injection device 15A and in Fig. 5
which is a cross-sectional view taken along the line 1-1 noted in Fig. 4, the injection
device 15 has the shape of a substantially rectangular solid, each side of which extends
in parallel to the X, Y or Z axis crossing each other at right angles. The injection
device 15 comprises a plurality of ceramic thin plates 15a-15f (hereinafter to be
referred to as "ceramic sheets") that are sequentially laminated (layered in order)
and compression bonded (bonded by pressure), and a plurality of piezoelectric/electrostrictive
elements 15g secured to the outer side face (plane along the X-Y plane in the positive
direction of Z axis) of the ceramic sheet 15f. This injection device 15A includes
a liquid supply passage 15-1, a plurality of chambers 15-2 which are independent from
each other (here, 7 pieces for each line, 14 pieces in total), a plurality of liquid
introduction holes 15-3 which make each of the chambers 15-2 communicate with the
liquid supply passage 15-1, a plurality of liquid ejection nozzles 15-4, one end of
which is substantially exposed to a liquid injection space 21 so that each of the
chambers 15-2 can communicate with the outside of the injection device 15A, and a
liquid filling port 15-5, inside it.
[0040] The liquid supply passage 15-1 is a space defined by the side wall face of an elliptic
(elongated circle-shaped) cut, formed in the ceramic sheet 15c, with its longer axis
and shorter axis running along the X axis direction and the Y axis direction, respectively,
the upper face which is the plane of the ceramic sheet 15b, and the lower face which
is the plane of the ceramic sheet 15-b.
[0041] Each of the plurality of chambers 15-2 is a longitudinal space (a liquid flow passage
having a longitudinal direction) defined by the side wall face of an elliptic (elongated
circle-shaped) cut, formed in the ceramic sheet 15-e, with its longer axis and shorter
axis running along the Y axis direction and X axis direction, respectively, the upper
face of the ceramic sheet 15d, and the lower face of the ceramic sheet 15f. One end
in the Y axis direction of each of the chambers 15-2 extends up to the upper section
of the liquid supply passage 15-1, and by means of using this one end, each of the
chambers 15-2 is connected to the liquid supply passage 15-1 through the hollow cylindrical
liquid introduction hole 15-3 with the diameter d provided in the ceramic sheet 15d.
Hereinafter, the diameter d is also to be simply referred to as "introduction hole
diameter d". The other end in the Y-axis direction of each of the chambers 15-2 is
connected to the other end of the liquid ejection nozzle 15-4. According to the above-mentioned
configuration, through and in the chamber 15-2 (flow passage), the liquid flows from
the liquid introduction hole 15-3 toward the liquid ejection nozzle 15-4.
[0042] Each of the plurality of liquid ejection nozzles 15-4 is formed by a hollow cylindrical
through hole (a liquid injection port, a liquid ejection port) 15-4a with the diameter
being D, being provided in the ceramic sheet 15a, one end of which (a liquid injection
port, an opening exposed to the liquid injection space) being substantially exposed
to the liquid injection space 21, and a series of hollow cylindrical through holes
15-4b - 15-4d formed in each of the ceramic sheets 15b-15d, respectively, the sizes
(diameters) of which becoming larger sequentially (in order) starting from the liquid
injection port 15-4a toward the chamber 15-2. The axis for each of the liquid ejection
nozzles 15-4 is in parallel to the Z-axis. Hereinafter, the diameter D is also to
be simply referred to as "nozzle diameter D".
[0043] The liquid filling port 15-5 is a space formed by the side wall of the hollow cylindrical
through holes provided in the ceramic sheets 15-d - 15-f at the end in the X-axis
positive direction of the injection device 15A and at the generally center in the
Y-axis direction of the injection device 15A, so that the liquid supply passage 15-1
can communicate with the outside of the injection device 15A. The liquid filling port
15-5 is connected to (communicates with) the upper section of the liquid supply passage
15-1 on a virtual (hypothetical, imaginal) plane located on the boundary plane between
the ceramic sheets 15d and 15c. The upper face of the ceramic sheet 15b, i.e. , section
(portion) of the liquid supply passage 15-1 being opposed to (confronting) this virtual
plane is a plane, which is in parallel to the virtual plane.
[0044] The shape and the size of each of the chambers 15-2 are additionally described here.
When each of the chambers 15-2 is cut at the center (i.e. the flow passage is cut)
in its longitudinal direction (Y-axis direction), with the plane (X-Z plane) crossing
at right angles the direction in which the liquid flows (liquid flowing direction),
thus obtained cross-sectional shape of the flow passage is substantially a rectangle.
The length L of the longer axis for the longitudinal-shaped flow passage (i.e. the
length L along the Y axis) and the length W of the shorter axis (i.e. the length W
along the X axis, and the length W of a side of the rectangle) are 3.5mm and 0.35mm,
respectively, and the height T (i.e. the length T along the Z axis, and the length
T of a side crossing said side of the rectangle at right angles) is 0.15mm. In other
words, in the rectangle which is the shape of the cross-section of the flow passage,
the ratio (T/W) of the length (height T) of a side crossing another side having the
piezoelectric/electrostrictive element at right angles to the length (shorter axis
W) of the side having the piezoelectric/electrostrictive element is 0.15/0.35 = 0.43,
and it is desirable that this ratio (T/W) is larger than 0 and smaller than 1 (i.e.
between 0 and 1). If the ratio (T/W) is selected in such a way (i.e. between 0 and
1), the oscillation energy (vibration energy) of the piezoelectric/electrostrictive
element 15g can be efficiently and promptly transferred to the fuel within the chamber
15-2.
[0045] Also, the diameter D of the end portion of the liquid ejection nozzle 15-4 (nozzle
diameter D), and the diameter d of the liquid introduction hole 15-3 are designed
to be 0.031mm and 0.025mm, respectively. In this case, the cross-sectional area S1
(= W × T) of the flow passage of the chamber 15-2 is desirably larger than the sectional
area S2 (= π·(D/2)
2) of the end portion 15-4a of the liquid ejection nozzle 15-4, and moreover, larger
than the sectional area S3 (= π·(d/2)
2) of the liquid introduction hole 15-3. Also, for atomizing liquid, the sectional
area S2 is desirably larger than the sectional area S3.
[0046] Each of the piezoelectric/electrostrictive elements 15g is slightly smaller than
each of the chambers 15-2 in a plan view (viewed from the Z-axis positive direction),
and secured to the upper face of the ceramic sheet 15f (wall face including the side
of the rectangular (quadrilateral), that is the cross-sectional shape of the flow
passage of the chamber 15-2). Each of the elements 15g is arranged inside of each
of the chambers 15-2 in the plan view. These piezoelectric/electrostrictive elements
15g are operated (driven) based on the drive voltage signal DV which is supplied to
an electrode-to-electrode (not shown in the drawing) formed on the upper face and
on the lower face of each of the piezoelectric/electrostrictive elements 15g, by and
from a drive voltage signal generation means (circuit) of the electric control unit
30, to deform the ceramic sheet 15f (the upper wall of the chamber 15-2), thereby
changing the volume of the chamber 15-2 by ΔV.
[0047] As to method for forming the ceramic sheets 15a - 15f, and for forming their laminated
(layered) body, a method comprising the following steps is employed.
1: a step, in which a green ceramic sheet is formed by means of using a powdered zirconia
with particles ranging in size from 0.1 to several µm's;
2. a step, in which stamping is carried out to the ceramic green sheet by using a
metallic molded punch and die to form cut-out sections corresponding to the cuts that
the ceramic sheets 15a - 15e shown in Fig. 5 have (i.e. cavities for the chamber 15-2,
liquid introduction hole 15-3, liquid supply passage 15-1, liquid ejection nozzle
15-4, and liquid filling port 15-5 (see Fig. 4).); and
3. a step, in which the ceramic green sheets are laminated and compression bonded,
then burned at 1550°C for 2 hours to form a single piece.
[0048] On the upper face of a section corresponding to the chamber section of the laminated
body of the ceramic sheets manufactured by the method described above, the piezoelectric/electrostrictive
element 15g having (interposed between) electrodes is formed. With the steps described
above, the injection device 15A is manufactured. As described above, when the injection
device 15A is formed as a single piece with zirconia ceramics, a high durability can
be maintained against frequent deformations of the wall face 15f caused by the piezoelectric/electrostrictive
element 15g due to the characteristics of the zironia ceramics, and the size of the
liquid injection device having the plurality of ejection nozzles 15-4, 15-4... can
be reduced to be several centimeters in the overall length. In addition, the device
can be easily manufactured at low cost.
[0049] The injection device 15A described above is secured to an injection device stationary
plate 15B, as shown in Figs. 2 and 3. This injection device stationary plate 15B has
a rectangle-shape which is slightly larger than the injection device 15A in a plan
view. The injection device stationary plate 15B includes through holes, not shown
in the drawings, in the position opposite to each liquid injection port 15-4a in the
injection device 15A, when securing the injection device 15A, so that each liquid
ejection port 15-4a is designed to be exposed to the outside through each of the thorough
holes. The injection device stationary plate 15B is secured to a retainer unit 15C
by being retained at its periphery.
[0050] The outside shape of the retainer unit 15C in the plan view is the same as that of
the injection device stationary plate 15B, and as shown in Fig. 1, the retainer unit
is secured to the intake pipe 20 of the internal-combustion engine at its periphery
with bolts which are not shown in the drawings. As shown in Fig. 2, this retainer
unit 15C has, at its center, a through hole, the diameter of which is slightly larger
than the diameter of the external barrel 14c of the electro-magnetic ejection valve
14. The external barrel 14c is inserted into this through hole.
[0051] As shown in Figs. 2 and 3, a sleeve (hermetically sealed space forming member) 15D
has a cylindrical shape. The internal diameter of the sleeve 15D is equal to the outer
diameter of the external barrel 14c of the electro-magnetic ejection valve 14, and
the outer diameter of the sleeve 15D is equal to the internal diameter of the thorough
hole in the retainer unit 15C. One end of the sleeve 15D is closed, and the other
end is open. As shown in Fig. 3, at the center of the closed end, an opening 15D-1
is provided, which has almost the same diameter as the liquid filling port 15-5 in
the injection device 15A. An O-ring groove 15D-1a is formed on the wall face on the
inner radius side forming the opening 15D-1. The groove 15D-1a is positioned at the
outer side of the closed end.
[0052] The external barrel 14c of the electro-magnetic ejection valve 14 is press-inserted
into the sleeve 15D from the open end of the sleeve 15D until it bottoms the inner
side of the closed end of the sleeve 15D, and then the sleeve 15D is press-inserted
into the thorough hole in the retainer unit 15C. At this time, an O-ring 16 inserted
into the O-ring groove 15D-1a comes into contact with the ceramic sheet 15f of the
injection device 15A.
[0053] As described above, the electro-magnetic ejection valve 14 and the injecting unit
15 are assembled as a single piece (part), and a hollow cylindrical hermetically sealed
space is formed between the ejection hole 14c-2 in the electro-magnetic ejection valve
14 (i.e. the leading closed end of the external barrel 14c of the electro-magnetic
ejection valve 14 in which the ejection hole 14c-2 is formed (i.e. the outer side
of the closed end) or the section which can be referred to as "an outer side of the
ejection hole forming face of the hollow cylindrical external barrel 14c") and the
liquid filling port 15-5 in the injection device 15A. In this state, the center axis
of the opening 15D-1 of the sleeve 15D (the center axis of the hollow cylindrical
hermetically sealed space) is aligned with the center axis of the liquid filling port
15-5 in the injection device 15A, and also, aligned with the center axis CL of the
needle valve. As described above, the sleeve 15D is placed between the ejection holes
14c-2 in the electro-magnetic ejection valve 14 and the liquid filling port (liquid
filling section) 15-5 in the injection device 15A, such that a hollow cylindrical
hermetically sealed space is formed between the ejection hole 14c-2 (the outer side
of the leading closed end of the external barrel 14) and the liquid filling port 15-5.
The hollow cylindrical hermetically sealed space has substantially the same diameter
as that of the liquid filling port 15-5, and the center axis of the hollow cylindrical
hermetically sealed space is aligned with the center axes CL of the liquid filling
port 15-5 and the needle valve.
[0054] Also, as described above, since the ejection hole 14c-2 is tilted by angle θ to the
axis CL of the needle valve 14d (i.e., the axis of the hollow cylindrical hermetically
sealed space), as the fuel ejected from the electro-magnetic ejection valve 14 travels
closer to the injection device 15A, in the inside of the opening 15D-1 in the sleeve
15D (i.e., in the hollow cylindrical hermetically sealed space), it spreads at angle
θ to the axis CL. In other words, a distance between the fuel ejected from the ejection
hole 14c-2 in the form of droplets of liquid and the center axis CL of the hollow
cylindrical hermetically sealed space increases, as a distance from the ejection hole
14c-2 to the liquid filling port 15-5 increases.
[0055] In this embodiment, the angle θ is determined so that before the fuel thus ejected
arrives at a wall face WP, which is formed (is defined) by the inner radius wall face
which forms the opening 15D-1 in the sleeve 15D (that is, the hollow cylindrical hermetically
sealed space) as well as by means of virtually extending the inner radius wall face
(excluding the inner radius wall face of the O-ring groove) till the extended portion
crosses a plane section PS of the liquid supply passage 15-1 (the plane section being
a portion of the upper face of the ceramic sheet 15b) (shown by an imaginary two-point-chain-line
in Fig. 3), the fuel can arrive at the plane section PS of the liquid supply passage
15-1.
[0056] In other words, the electro-magnetic ejection valve 14 is placed and configured so
that the eject flow line (shown by one-point chain line DL in Fig. 3) for the liquid
ejected from the ejection hole 14c-2 directly crosses the plane section PS of the
liquid supply passage 15-1, without crossing the side wall WP which is formed by means
of virtually extending the side wall 15D-1 of the hollow cylinder forming the hermetically
sealed space in the sleeve 15D to the plane section SP of the liquid supply passage
15-1, or the side wall 15D-1. That is, the liquid ejected crosses neither the virtual
side wall WP nor the inner side wall of the opening 15D-1.
[0057] Due to the configuration as described above, the fuel, which is ejected from the
ejection hole 14c-2 in the electro-magnetic ejection valve 14 and supplied to the
liquid supply passage 15-1 through the liquid filling port 15-5, is then introduced
into each of the chambers 15-2 through each liquid introduction hole 15-3. And after
being given an oscillation energy in the individual chambers 15-2, the fuel is injected
through the liquid ejection nozzle 15-4, and from the liquid injection port 15-4a,
into the intake pipe 20 in the form of atomized droplet, through the through hole
in the injection device stationary plate 15B.
[0058] As shown in Fig. 1, the electric control unit 30 is connected to an engine rotational
speed sensor 31 and an intake pipe pressure sensor 32, and is configured in such a
manner as to determine the fuel amount required for the internal-combustion engine,
after obtaining the engine rotational speed N and the intake pipe pressure P from
these sensors, and send out (supply) a high-level signal (signal for opening the valve)
as the valve drive signal INJ for the time corresponding to the fuel amount. By this
configuration, the needle valve 14d of the electro-magnetic ejection valve 14 is forced
to move in response to the high-level signal so as to open the ejection hole 14c-2
to eject the fuel from the ejection hole 14c-2.
[0059] In addition, the electric control unit 30 has a built-in drive signal generation
circuit for supplying a drive voltage signal DV of a frequency f (a driving frequency
with period T=1/f) to between electrode-to-electrode (electrodes, not shown) for the
piezoelectric/electrostrictive element 15g. In this case, the driving frequency f
is set to be equal to the resonance frequency (specific oscillation frequency) of
the injection device 15A. The resonance frequency is determined by the structure of
the chamber 15-2, the structure of the liquid ejection nozzle 15-4, the nozzle diameter
D, the introduction hole diameter d, the shape of the section causing deformation
in the ceramic sheet 15f by the piezoelectric/electrostrictive element 15g, and types
of the liquid. For example, the driving frequency is set to around 50 kHz.
[0060] Here, referring to Fig. 6, the time-relationship between the valve drive signal INJ
and the drive voltage signal DV is described. The electric control unit 30 starts
applying the drive voltage signal DV to the piezoelectric/electrostrictive element
15g, at the time T1 which is the same as the time t1 when the valve drive signal INJ
to the electro-magnetic ejection valve 14 rises (changes from a low-level signal to
a high-level signal), or alternatively, at the time t0 immediately before the time
t1, and the unit 30 continues the application of the drive voltage signal DV to the
piezoelectric/electrostrictive element 15g until the time t4, which is only the specified
time behind the time t3 when the valve drive signal INJ to the electro-magnetic ejection
valve 14 falls (changes from a high-level signal to a low-level signal), and (the
time t4 being the time) when the pressure of the liquid within the liquid supply passage
15-1 drops to (becomes equal to) the steady-state pressure during the electro-magnetic
ejection valve 14 is in the closed state. The unit 30 ends the application of the
drive voltage signal DV at the time t4.
[0061] Next, operations of the thus configured liquid injection apparatus are described
below. The electric control unit 30 determines the valve drive signal INJ (the length
of a high-level signal), based on the engine running state, such as the engine rotational
speed N and the intake pipe pressure P, and also determines the timing (time t1 noted
in Fig. 6) to output the valve drive signal INJ. In addition, when the time t0, which
is only the specified time earlier than the time t1, comes, the electric control unit
30 starts adding (supplying) the drive voltage signal DV with the frequency f to the
electrode-to-electrode for the piezoelectric/electrostrictive element 15g, and supplies
the valve drive signal INJ to the electro-magnetic ejection valve 14 at the time t1.
[0062] When the time t2 comes, which is slightly later than the time t1, (in other words,
when the invalid injecting time of the electro-magnetic ejection valve elapsed), the
ejection hole 14c-2 is opened because the needle valve 14d is moved, and from the
ejection hole 14c-2, the apparatus starts ejecting and supplying the fuel in the fuel
passage 14b into the liquid supply passage 15-1 in the injection device 15A, through
the hollow cylindrical hermetically sealed space in the sleeve 15D and the liquid
filling port 15-5 in the injection device 15A. As a result, the pressure of the liquid
within the liquid supply passage 15-1 starts rising, as shown in Fig. 6 (B).
[0063] After the time t2, when the pressure of the fuel in the chamber 15-2 rises up to
the sufficient pressure, the fuel is pushed out (injected) toward the liquid injection
space in the intake pipe 20, from the end face of the liquid injection port 15-4a.
At this time, since an oscillation energy caused by the operation of the piezoelectric/electrostrictive
element 15g is added to the fuel in the chamber 15-2, a constricted area is formed
in the injected fuel. Therefore, the fuel is separated from the constricted area as
if being torn off at its leading end. As the result of this, the equally and finely
atomized fuel is injected into the intake pipe 21.
[0064] In this case, the apparatus is configured so that the ratio (V/Q) is 0.03 or less,
where Q (cc/minute) represents the eject amount (eject flow rate) per unit time of
the liquid ejected from the electro-magnetic ejection valve 14, and V (cc) represents
the volume of the liquid flow passage formed from the electro-magnetic ejection valve
14 (a leading end of the ejection holes 14c-2) to the leading end of the liquid ejection
nozzle 15-4 of the injection device 15A.
[0065] Here, the volume V means the total volume of the hollow cylindrical hermetically
sealed space formed by the sleeve 15D, liquid filling port 15-5, liquid supply passage
15-1, chambers 15-2, liquid introduction holes 15-3, and liquid ejection nozzles 15-4.
[0066] As shown in Fig. 6, this embodiment sets the time when the valve drive signal INJ
is a high-level signal, so that this time is only within the time when the intake
valve 22 in the internal-combustion engine is in the open state. In other words, when
the fuel injected by the liquid injection apparatus 10 arrives at the intake valve
22, the intake valve 22 has already been in the open state, so that the fuel is directly
sucked up into the cylinder without attaching (adhering) to the rear (back) face of
the intake valve 22. Thus, since the atomized and injected fuel is directly sucked
up into the cylinder, there is no or little possibility of the fuel attaching (adhering)
to the wall face of the intake valve 22 or intake pipe 20 and the like. Therefore,
the fuel consumption of the internal-combustion engine can be improved, and the amount
of not-burnt (unburned) gas contained in the emission can be reduced.
[0067] Preferably, the velocity of the atomized fuel (droplets of liquid, sprayed droplets)
injected from the liquid ejection nozzle 15-4 is varied with respect to the lift amount
of the intake valve 22, and/or the suction flow velocity (wind velocity) in the intake
pipe 20. According to such a preferable embodiment, it is more likely that the atomized
and injected fuel can be directly sucked up into the cylinder without attaching to
the wall face. The velocity of the atomized fuel injected from the liquid ejection
nozzle 15-4 can be varied, by means of varying the waveform of the drive voltage signal
DV to the piezoelectric/electrostrictive element 15g (particularly, the rising speed
of the signal DV, or the maximum voltage of the signal DV), or by varying the pressure
of the fuel (fuel pressure) to be supplied to the electro-magnetic ejection valve
14. The fuel pressure can be changed, by means of varying the regulation pressure
of the pressure regulator 13, or varying the eject pressure of the pressurizing pump
if the pressure regulator 13 is not provided.
[0068] As described above, according to the liquid injection apparatus with respect to the
embodiment of the present invention, since the fuel is pressurized by the pressurizing
pump 11, and the fuel is injected into the liquid injection space 21 in the intake
pipe 20 due to the pressure, the apparatus can stably inject the intended amount of
fuel, even if the pressure in the liquid injection space 21 (suction pressure) changes.
[0069] In addition, oscillation energy is given to the fuel by the volume change of the
chamber 15-2 in the injection device 15A, and the fuel is injected from the liquid
ejection nozzle 15-4, with being atomized. As a result, the liquid injection apparatus
can inject extremely finely atomized droplets of liquid. Moreover, as the injection
device 15A comprises a plurality of chambers 15-2 and a plurality of ejection nozzles
15-4, even if air bubbles are formed in the fuel, the air bubbles are easily divided
finely. As a result, significant fluctuation in the amount of injection caused by
the presence of air bubbles can be avoided.
[0070] Also, since the direction in which the fuel is ejected from the ejection hole 14c-2
is determined, such that the distance of the fuel ejected from the ejection hole 14c-2
from the center axis CL of the hollow cylindrical hermetically sealed space increases,
as the distance from the ejection hole 14c-2 in the electro-magnetic ejection valve
14 to the liquid supply passage 15-1 along the center axis CL increases, the flow
of the ejected fuel is produced in a wide area in the hollow cylindrical hermetically
sealed space. As a result, air bubbles are hardly formed, especially at corners in
the vicinity of the ejection hole 14c-2 of the electro-magnetic ejection valve 14
in the hermetically sealed space (marked by blackened triangle in Fig. 3), or removal
performance to remove (exclude) air bubbles generated (formed) at the corners is improved.
Therefore, in this liquid injection apparatus, since the rise of the fuel pressure
is hardly hindered by air bubbles, the pressure of the fuel can be increased as expected,
thereby enabling the apparatus to inject the required amount of injection of droplets
of the fuel at the required injection timing, according to the requirements of mechanical
apparatuses including the internal-combustion engine.
[0071] Further, the above-mentioned liquid injection apparatus is configured such that by
the time when liquid ejected from the electro-magnetic ejection valve 14 is eventually
injected from the ejection nozzle 15-4 into the liquid injection space 21, a flow
of the liquid is bent at substantially right angles at least once (in this embodiment,
4 times).
[0072] That is, in this liquid injection apparatus, the flow of the liquid ejected from
the electro-magnetic ejection valve 14 is first bent at right angles at the joint
section of the liquid filling port 15-5 and the liquid supply passage 15-1, as the
liquid filling port 15-5 crosses the liquid supply passage 15-1 at right angles. Next,
the flow of the liquid is bent at right angles at the joint section of the liquid
supply passage 15-1 and the liquid introduction hole 15-3, as the longer axis direction
of the liquid supply passage 15-1 is in parallel with the X axis, and the center axis
of the liquid introduction hole 15-3 is in parallel with the Z axis.
[0073] Moreover, since the longer axis of the chamber 15-2 is in parallel with the Y axis,
and the center axis of the liquid introduction hole 15-3 is in parallel with the Z
axis, the flow of the liquid is bent at right angles at the joint section of the chamber
15-2 and the liquid introduction hole 15-3. Also, since the longer axis of the chamber
15-2 is in parallel with the Y axis, and the axis of the liquid ejection nozzle 15-4
is in parallel with the Z axis, the flow of the liquid is again bent at right angles
at the joint section of the chamber 15-2 and the liquid ejection nozzle 15-4.
[0074] In such configurations as described above, since the flow of the liquid ejected from
the electro-magnetic ejection valve 14 is bent at substantially right angles at least
once, pulsation of the liquid pressure caused by opening of the electro-magnetic ejection
valve 14 can be reduced (attenuated), and thereby the apparatus can stably inject
droplets of liquid. In otherwords, the dynamic pressure of the liquid caused by opening
of the electro-magnetic ejection valve 14 becomes the static pressure, and the fuel
is injected under this static pressure. As a result, the fuel can be stably injected
from each ejection nozzle.
[0075] Especially, this liquid injection apparatus comprises a plurality of chambers 15-2,
which are connected to the liquid supply passage 15-1 in common to chambers 15-2,
and furthermore, the apparatus is configured such that the flow of the liquid ejected
from the electro-magnetic ejection valve 14 is bent at generally right angles at the
joint section of a liquid filling port 15-5 and the liquid supply passage 15-1. Thus,
it is possible to stabilize the pressure of the liquid within the liquid supply passage
15-1 and therefore within the chambers 15-2. Accordingly, droplets of liquid ejected
from each of ejection nozzles 15-4, 15-4... connected to each of the chambers 15-2,
15-2... can be made uniform, since the pressure of the liquid in each of the chambers
15-2, 15-2...becomes the static pressure and thus stabilized.
[0076] In addition, the electro-magnetic ejection valve 14 is arranged and configured such
that the ejected flow line of the liquid (fuel) (shown by 1-point chain line DL in
Fig. 3) directly crosses the plane section PS of the liquid supply passage 15-1, without
crossing a side wall WP which is formed by the side wall of the opening 15D-1 forming
the hollow cylindrical hermetically sealed space in the sleeve 15D, or a side wall
WP defined by means of virtually extending the side wall of the opening 15D-1 down
to the plane section PS of the liquid supply passage 15-1 (the upper face of the ceramic
sheet 15b).
[0077] As the result of this configuration and arrangement, since the liquid ejected from
the electro-magnetic ejection valve 14 arrives at the plane section SP of the liquid
supply passage 15-1 with keeping its kinetic energy (flow velocity) in high state,
the liquid is strongly reflected, on this plane section PS, to the side of the ejection
hole 14c-2 in the hollow cylindrical hermetically sealed space. As the result of this
reflection, the flow of the reflected liquid can remove (exclude) air bubbles staying
at the corners (shown by blackened triangle in Fig. 3) in the vicinity of the ejection
hole 14c-2 in the hollow cylindrical hermetically sealed space, thereby reducing the
amount of air bubbles in the liquid. Due to this reduction, in this liquid injection
apparatus, the pressure rise of the liquid is more hardly hindered by air bubbles,
and the pressure of the liquid can be increased as expected. Therefore, this enables
the apparatus 10 to inject the required amount of injection of droplets of liquid
at the required injection timing, as the internal-combustion engine requires.
[0078] Also, as the apparatus is configured such that the ratio (V/Q) is 0.03 or less, where
Q represents the eject amount (eject flow rate) (cc/minute) of the liquid ejected
from the electro-magnetic ejection valve 14 per unit time, and V represents the volume
(cc) of the liquid flow passage formed from the electro-magnetic ejection valve 14
to the leading end of the ejection nozzle 15-4 in the injection device 15A, the volume
V does not become excessively large relatively to the eject flow rate. Therefore,
since the time period until the pressure of the liquid within the ejection nozzle
15-4 in the injection device 15A starts rising, from the electro-magnetic ejection
valve 14 started ejecting the liquid, can be shortened, the apparatus can inject droplets
of liquid at the intended timing.
[0079] Furthermore, the above-mentioned liquid injection apparatus advances the start of
generating the drive voltage signal DV than the start of generating the valve drive
signal INJ, and at the same time, it retards the end of the drive voltage signal DV
than the end of the valve drive signal INJ. As the result of this, since oscillation
energy is always given to the fuel to be injected, the apparatus could securely inject
the atomized fuel even at the injecting start time or ending time, and in addition,
power consumption could be reduced, because the apparatus generates the drive voltage
signal only when required.
[0080] Moreover, as the axis of the individual liquid ejection nozzle 15-4 is in parallel
to the Z-axis, the droplets of liquid ejected from the ejection nozzles 15-4 to the
liquid injection space 21 will not substantially cross each other while flying, and
will not become larger droplets of liquid by coming into collision with each other
in the liquid injection space 21. Due to the reasons, satisfactory fuel spray in equally
atomized state can be embodied.
[0081] In the above-mentioned embodiment, the strength of oscillation to be given to the
fuel varies depending on the potential difference to be added to between the electrode-to-electrode,
not shown in the drawing, provided on the upper face and the lower face of the piezoelectric/electrostrictive
element 15g (i.e., the maximum voltage of the drive voltage signal DV, the strength
of the electric field to be added to the piezoelectric/electrostrictive element 15g),
or the thickness of the ceramic sheet 15f (the upper wall) of the chamber 15-2. In
this embodiment, it is designed that the ratio V/ΔV (i.e., chamber volume/amount of
volume change) is 1500, where ΔV denotes the amount of the volume change of the chamber
15-2, obtained by means of deforming the ceramic sheet 15f by the operation of the
piezoelectric/electrostrictive element 15g, and V denotes the volume of the chamber
15-2. Here, the value of this ratio V/ΔV is preferably 2 or more and 3000 or less,
and particularly, 2 or more and 1500 or less.
[0082] This is because if the value of the ratio (chamber volume/amount of volume change)
exceeds 3000, the energy amount of oscillation to be transferred to the liquid within
the chamber 15-2 is reduced (is too small), and sufficient atomizing of the fuel cannot
be embodied. On the other hand, if the value of the ratio (chamber volume/amount of
volume change) is smaller than 2, the pressure of the liquid within the chamber 15-2
significantly fluctuates, thereby causing the eject amount (injecting flow rate) to
be unstable, and especially, if the liquid is a volatile liquid, such as gasoline
fuel, it becomes difficult to inject stably the liquid because of the large amount
of air bubbles formed in the liquid.
[0083] With the above-mentioned conditions, the droplet diameter of the gasoline injected
is 30 µm, equal size, thereby resulting in the improvement of fuel consumption and
reduction of toxic emission.
[0084] In the liquid injection apparatus of the above embodiment, an experiment was conducted
for studying the relationship among the nozzle diameter D in the injecting unit 15
(injection device 15A), the introduction hole diameter d, and the droplet ejecting
state. In the experiment, the injection device 15A was used, in which the length L
of the longer axis of the chamber 15-2 being 3.5mm, and the length W and the height
T of sides of the cross-section of the chamber 15-2 are 0.35mm and 0.15mm, respectively,
and as the ejecting liquid, gasoline was used. Also, at the time of injecting (at
the time of ejecting), the pressure of the liquid within the chamber 15-2 was increased
up to 0.1 Mpa, and at the same time, the drive voltage signal DV with the driving
frequency 45 kHz, and the maximum voltage V0 of the signal being 20V was supplied
to the piezoelectric/electrostrictive element 15g. The following table 1 shows the
result of the experiment. In the experiment, the state in which the size of the droplet
was smaller than the nozzle diameter D at the position which was only 5mm away from
the end portion of the liquid injection port 15-4a to the side of the injecting space,
and injecting was conducted stably was considered to be a satisfactory ejecting state
(in the Table 1, shown by "○"), and the other cases were considered to be fault (in
the Table 1, shown by "×").
[Table 1]
Sample
Name |
Nozzle
Diameter
D(mm) |
Introduction
hole
Diameter
d(mm) |
Nozzle Diameter/
Introduction hole
Diameter (D/d) |
Elect State |
Sample 1 |
0.031 |
0.005 |
6.200 |
× (No stability) |
Sample 2 |
0.031 |
0.007 |
4.429 |
○ |
Sample 3 |
0.031 |
0.025 |
1.240 |
○ |
Sample 4 |
0.025 |
0.031 |
0.806 |
× (No stability) |
Sample 5 |
0.031 |
0.031 |
1.000 |
× |
Sample 6 |
0.050 |
0.007 |
7.143 |
× |
Sample 7 |
0.050 |
0.025 |
2.000 |
○ |
[0085] As can be seen from Table 1, when the ratio of the nozzle diameter D to the introduction
hole diameter d (D/d) became larger than 6.200, stable injecting was not conducted
(see Sample 1). The reason for this is thought that if the introduction hole diameter
d is excessively smaller than the nozzle diameter D, the flow passage resistance at
the liquid introduction hole 15-3 becomes excessive, thus the liquid amount flowing
into the chamber 15-2 becomes insufficient. Therefore, desirably, the ratio D/d must
be smaller than 6.200, (preferably smaller than 5.000, or more preferably, smaller
than 4.429 (see Sample 2)).
[0086] Also, understood from Table 1, when the ratio D/d was smaller than 1.000, stable
eject was not performed (see Sample 5). The reason for this is thought that because
the introduction hole diameter d is excessively larger than the nozzle diameter D,
oscillation (oscillation energy) of the piezoelectric/electrostrictive element 15g
added to the liquid was absorbed up in (on the side of) the liquid supply passage
15-1 through the liquid introduction hole 15-3, thus the oscillation (oscillation
energy) failed to be sufficiently added to the liquid to be injected from the chamber
15-2 through the ejection nozzle 15-4.
[0087] Therefore, in order to allow the oscillation of the piezoelectric/electrostrictive
element 15g to be sufficiently transferred to the liquid to be injected, the apparatus
is advantageously configured such that the ratio D/d is larger than 1.000 (preferably
larger than 1.240), in other words, the area of the cross-section at one end of the
liquid eject nozzle 15-4 which is exposed to the liquid injection space, defined by
the nozzle diameter D (cross-sectional area of the liquid injection port 15-4a) is
larger than the cross-sectional area of the liquid introduction hole 15-3 defined
by the introduction hole diameter d.
[0088] By this configuration, the oscillation energy of the piezoelectric/electrostrictive
element 15g to be added to the liquid within the chamber 15-2 is hardly attenuated
in the liquid supply passage 15-1 through the liquid introduction hole 15-3, thus
the oscillation energy is efficiently transferred to the liquid to be injected from
one end of the ejection nozzle 15-4a, so that the liquid can be securely atomized.
[0089] When similar experiments were conducted by means of using a variety of values for
the nozzle diameter D, the experiments showed that the nozzle diameter D is desirably
smaller than 0.1 mm, and more desirably 0.02 - 0.04 mm. This is because if the nozzle
diameter D is larger than 0.1 mm, atomizing of the droplets of liquid to be injected
becomes difficult, or if the nozzle diameter D is smaller than 0.02 mm, dirt or dust
included in the liquid (fuel) is easily clog the liquid injection port 15-4, thereby
causing practical utility to be impaired.
[0090] Furthermore, in the embodied liquid injection apparatus, studies were made by means
of giving the potential difference in the form of a sinusoidal wave (a sine wave)
with a frequency f (a drive voltage signal of a driving frequency f = 1/T, period
T) to between the electrode-to-electrode for the piezoelectric/electrostrictive element
15g, to examine the maximum amount of displacement of the piezoelectric/electrostrictive
element 15g (in Fig. 5, the maximum amount of displacement in the Z axis direction
of the piezoelectric/electrostrictive element 15g). Fig. 8 shows the result of the
experiment. Here, the vertical axis shown in Fig. 8 denotes the ratio (D
f/D
o) of the maximum amount of displacement D
f of the piezoelectric/electrostrictive element 15g at each driving frequency f, to
the maximum displacement D
o of the piezoelectric/electrostrictive element 15g when a driving frequency f is 5
kHz.
[0091] As shown in Fig. 8, the ratio (D
f/D
o) becomes the largest, when a driving frequency f is in the vicinity of 50 kHz. The
frequency in the vicinity of 50 kHz equals the resonance frequency (intrinsic oscillation
frequency) of the injection device 15A defined by the structure of the chamber 15-2,
the structure of the liquid ejection nozzle 15-4, the nozzle diameter D, the introduction
hole diameter d, the shape of the section which causes deformation of the ceramic
sheet 15f of the piezoelectric/electrostrictive element 15g, and types of the liquid.
In other words, the experiments show that by means of allowing the driving frequency
f of the drive voltage signal DV to be equal to the frequency in the vicinity of the
resonance frequency of the injection device 15A (injecting unit 15), the piezoelectric/electrostrictive
element 15g can produce larger oscillation, even if the amplitude of the drive voltage
signal DV is the same, and the pressure of the liquid can be heavily oscillated with
a furthermore smaller energy. The findings show that, in the liquid injection apparatus
according to the present invention, desirably, the driving frequency f of the piezoelectric/electrostrictive
element 15g is set to 0.7 to 1.3 times of the frequency (resonance frequency) which
is in the vicinity of the resonance frequency of the injection device 15A (i.e., within
±30% of the resonance frequency), and if the driving frequency f is set as described
above, the wall face of the injection device (injecting unit) can be oscillated heavily
with less energy, thus the liquid injection apparatus can be reduced its energy consumption.
[0092] As described above, by the liquid injection apparatus according to the present invention,
the fuel as liquid cab be finely atomized into uniform sizes and injected at the liquid
injection space. The present invention is not limited to the above-mentioned embodiment,
but a variety of modified embodiments can be employed within the coverage of the present
invention. For example, the above-mentioned embodiment is configured such that the
flow of the liquid is bent 4 times at generally right angles by the time when the
liquid ejected from the electro-magnetic ejection valve 14 is injected to the liquid
injection space 21 from the ejection nozzle 15-4, however, as shown in Fig. 9, the
flow of the liquid may be bent only once at generally right angles, or as shown in
Fig. 10, the flow of the liquid may be bent only twice at generally right angles.
Also, the liquid injection apparatus according to the above-mentioned embodiment was
applied to the internal-combustion engine, but it can be applied to other mechanical
apparatuses, which form their material with atomized droplets of raw material of a
liquid.
[0093] The liquid injection apparatus according to the above-mentioned embodiment was applied
to the gasoline internal-combustion engine of the type for injecting fuel into the
intake pipe (suction port), however, it is also effective to apply the droplet injecting
apparatus according to the present invention to the so-called "direct injection type
gasoline internal combustion engine" which directly injects the fuel into the cylinder.
In other words, if the fuel is directly injected into the cylinder with the electrically
controlled fuel injection apparatus using the conventional fuel injector, the fuel
can be built-up between the cylinder and the piston (in the crevice), and there are
some cases in which the amount of incompletely combustedHC (hydrocarbon) increased.
On the contrary, when the fuel is directly injected into the cylinder, by means of
using the liquid injection apparatus according to the present invention, as the fuel
is injected into the cylinder in the atomized state, the amount of the fuel attaching
(adhering) to the wall face in the cylinder can be reduced, or the amount of fuel
entering the crevice located between the cylinder and the piston can be reduced, thereby
leading up to the reduction in the eject amount of incompletely combusted HC.
[0094] It is also effective to use the droplet injecting apparatus according to the present
invention as the direct injection injector for the diesel engine. In other words,
in the conventional injector, there is the problem that the atomized fuel cannot be
injected, because the fuel pressure is low especially when the engine is in the low-loaded
state. In such a case, if a common-rail injection apparatus is used, the pressure
of the fuel can be increased to some extent even when the engine rotational speed
is low, and atomizing of the injecting fuel can be accelerated, but the fuel pressure
is still low compared to that when the engine rotational speed is high, and the fuel
cannot be sufficiently atomized. On the contrary, since the liquid injection apparatus
according to the present invention atomizes the fuel by the operation of the piezoelectric/electrostrictive
element 15g, the apparatus can inject the fuel in the sufficiently atomized state,
regardless of the loaded state of the engine (i.e., even if the engine is in the low-loaded
state).
While illustrative and presently preferred embodiments of the present invention have
been described in detail herein, it is to be understood that the inventive concepts
may be otherwise variously embodied and employed and that the appended claims are
intended to be construed to include such variations except insofar as limited by the
prior art.